Unlock true potentials plus easy revamps and upgrades – plant-wide

A reactor or reaction system has not been treated as another unit operation in a process plant – like a separator, settler, heat exchanger or a compressor. It is usually treated as a black box where all upstream operations feed into and downstream operations begin. Rest of the plant design with all unit operations are geared to meet the needs of the feed and narrow feed/ operating conditions and to treat the effluents according to original design of the reactor. This is partly due to trade secrets held by reactor vendors and perceived risk.

But reactor is the heart of the plant. And it is a black box – no more.
Its design and development to de-bottlenecking are now made simple.

Industrial reactor as the heart of the plant digital twin

Unlock the full potentials of your plant now

  • By treating each reactor as another unit operation and its true optimization by going beyond narrow boundaries of designs and operations – possibly locked in by original design
  • Optimized for new/ changed feedstock/ feedstock composition
  • Optimized for new/ changed product/ product composition/ market demand
Plant-wide optimization schematic digital twin
  • Leading to saving in upstream and/or downstream processing costs due to improved/new reactor feed and effluent conditions or better yield

Although original CAPCOST of a reactor may be only 10-30% of total plant CAPCOST a substantial saving in OPCOST of the up- and downstream processing units by the new and true or full plant optimization process may lead to substantially improved profit from the operating plant

Reactor revamp benefits: lower OPCOST and higher yield

Now you can* also carry out revamps and upgrades of most reactors as you need and almost as easily as another unit of your plant with or without DIFREX help

*Barring legal constraints

Yield and OPCOST optimization digital twin

Frequently Asked Questions

New Unit Operation Reactor Design treats the reactor as an integrated unit operation, making it easier to optimize the entire process plant for higher efficiency, lower costs, and better performance.

Reactor Process Optimization improves reactor operating conditions, reaction performance, and process efficiency to increase product yield while reducing energy consumption and operating costs.

Treating the reactor as a unit operation enables better integration with upstream and downstream processes, helping improve productivity, flexibility, and overall plant economics.

Yes. Reactor process optimization helps identify opportunities for de-bottlenecking, revamps, feedstock changes, and process improvements without major plant modifications.

These solutions are ideal for process engineers, plant operators, EPC companies, technology developers, and chemical manufacturers looking to optimize existing or new reactor systems.